Expandable Bolt with Shielded Tip

ABSTRACT

The present invention includes a rock bolt having a longitudinally expandable tube. The tube includes a longitudinally extending depression that defines a temporary enclosed longitudinal passageway. The rock bolt further includes a shielded distal end to prevent debris from entering the temporary enclosed longitudinal passageway. The distal end is shielded using a cover which may be a plug or a cap and may provide a rounded tip for the rock bolt. The plug may be spherical. The cap may be attached such that its proximal end abuts the distal end of the rock bolt, is inserted into the distal end of the rock bolt, or extends beyond the distal end and along the sidewall of the rock bolt. The present invention also includes a method of making such a rock bolt and a method of using such a rock bolt.

CROSS REFERENCE TO RELATED APPLICATIONS

The present application is a continuation of U.S. application Ser. No.13/118,678, filed May 31, 2011, entitled “Expandable Bolt with ShieldedTip”, and claims-priority from U.S. Provisional Patent Application No.61/351,328, filed Jun. 4, 2010, entitled “Expandable Bolt with ShieldedTip”, all of which are herein incorporated by reference.

BACKGROUND OF THE INVENTION

1. Field of the Invention

This invention relates to a rock bolt having an expandable tube and ashielded distal end, a method of making such a rock bolt, and a methodof using such a rock bolt.

2. Description of Related Art

Rock bolts are used in underground mines, such as coal mines, to supportthe roof and ribs. Installation of conventional rock bolts involvesdrilling a borehole into the rock to a desired depth using an elongateddrilling tool (termed the drill steel), removing the drill steel fromthe borehole, optionally inserting adhesive resin cartridges, andretaining the cartridges in the blind end of the borehole while a bolt,optionally bearing an expansion anchor, is installed into the borehole.The free end of the bolt extending out of the borehole is received by achuck of a bolting machine. The bolting machine rotates the bolt withinthe borehole to mix the adhesive resin and/or expand the expansionanchor.

Other rock bolts comprise a longitudinally expandable tube that includesa longitudinally extending depression between two curved outer portionswhere the tube is partially collapsed on itself. The ends of the tubeare folded over to create two enclosed cavities in the curved outerportions of the tube while a temporary passageway defined by thedepression remains open on the ends. After placing the rock bolt in thepre-drilled borehole, pressurized fluid is delivered into the twocavities to force the depression outward, expand the tube, and compressit against the surrounding rock. Until the expansion has been completed,the ends of the passageway defined by the depression are open so thatdebris from the borehole can fall into the passageway defined by thedepression.

SUMMARY OF THE INVENTION

The present invention includes a rock bolt having a longitudinallyexpandable tube. The tube includes a longitudinally extending depressionthat defines a temporary, enclosed longitudinal passageway. The rockbolt further includes a cover on the distal end of the rock bolt toprevent debris from entering the temporary, enclosed longitudinalpassageway, ease insertion of the rock bolt into the borehole, andassist in alignment of the rock bolt in the borehole. The cover may be aplug or a cap and may provide a rounded tip for the rock bolt. The plugmay be spherical. The cap may be attached such that its proximal endabuts the distal end of the rock bolt, is inserted into the distal endof the rock bolt, or extends beyond the distal end and along thesidewall of the rock bolt.

The present invention also includes a method of manufacturing a rockbolt, including providing an expandable member including an expandabletube and an end fitting where the expandable tube has a longitudinallyextending depression disposed between a pair of outer portions of thetube, the exterior of the tube defines a temporary, enclosedlongitudinal passageway having an open distal end, and the outerportions of the tube have closed distal ends; and enclosing theexpandable member with a cover such that a distal open end of thetemporary, enclosed longitudinal passageway of the expandable tube iscovered. The cover may be a plug or a cap and may provide a rounded tipfor the rock bolt. The method may also include placing a stiffening tubeon a proximal end of the expandable tube such that the stiffening tubesurrounds the proximal end of the expandable tube and has an openingthat aligns with a corresponding opening in the expandable tube, therebyproviding fluid communication to an interior of the expandable tube.

A method of using a rock bolt, including providing a rock bolt having anexpandable member including an expandable tube having a temporary,enclosed longitudinal passageway with an open distal end; and a cover ata distal end of the rock bolt covering the temporary longitudinalpassageway; drilling a borehole in rock; placing the rock bolt in theborehole; expanding the tube by providing pressurized fluid to theinterior of the tube, thereby providing frictional engagement between anexterior of the tube and an interior of the borehole; and draining thefluid from the interior of the tube. The cover may be a plug or a capand may provide a rounded tip for the rock bolt.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a side view of a rock bolt produced according to the presentinvention;

FIG. 2 is a cross-section taken along lines 1-1 of FIG. 1;

FIG. 3 is a cross-section taken along lines 2-2 of FIG. 1, as installedin rock strata;

FIG. 4 is a longitudinal cross-section of the distal end of a rock boltaccording to one embodiment of the present invention;

FIG. 5 is a longitudinal cross-section of the distal end of a rock boltaccording to a second embodiment of the present invention;

FIG. 6 is a longitudinal cross-section of the distal end of a rock boltaccording to a third embodiment of the present invention; and

FIG. 7 is a longitudinal cross-section of the distal end of a rock boltaccording, to a fourth embodiment of the present invention.

DETAILED DESCRIPTION OF THE INVENTION

Referring now to the drawing figures in which like reference numbersrefer to like elements, FIG. 1 shows a rock bolt 2 which includes anexpandable tube 4 having an initial cross-sectional profile as shown inFIG. 2. The tube 4 is partially collapsed upon itself (such as byrolling or drawing) so as to provide a depressed region 6 between twocurved outer portions 8, 10 extending longitudinally along the tube 4.The tube 4 is produced from a steel alloy or the like having sufficientstrength to function in rock support, even after deformation frominternal hydraulic pressure as described below. A first stiffening tube14, having a sidewall and two open ends, is attached to and surrounds aproximal end 15 of the tube 4. A lip 18 may extend from stiffening tube14 for engaging with a rock surface when the rock bolt 2 is inserted inthe borehole.

A second stiffening tube 20, having a sidewall and two open ends, isattached to and surrounds a distal end 21 of tube 4 leaving the end ofthe tube 4 uncovered. A cover 22 covers the opening in a distal end 23of second stiffening tube 20, the tube 4, or both and may be fixedthereto by welding or the like. The outer curved portions 8, 10 of tube4 abut one another to define a temporary main passageway 26 as well asinterior passageways 28, 30. Main passageway 26 is open at the distalend 21 of tube 4 while interior passageways 28, 30 are closed as shownin FIGS. 4-7. As shown in FIG. 1, the first stiffening tube 14 definesan opening 34 which is aligned with an opening (not shown) in tube 4,such that the openings are in fluid communication with interiorpassageways 28, 30.

In operation, a borehole is drilled into the rock to the desired depthand the bolt 2 is inserted through a bearing plate and into theborehole. A source of pressurized fluid, such as water, is deliveredthrough the opening 34 of the first stiffening tube 14 and an opening intube 4 into interior passageways 28, 30. When passageways 28, 30 arefilled, the further addition of fluid creates sufficient hydraulicpressure to force open the tube 4, such that passageways 28, 30 areconjoined as an interior 35 of the tube 4 expanding the tube 4, andultimately compressing the tube 4 against the surrounding rock of theborehole. See FIG. 3. As a result, main passageway 26 no longer exists.When the tube 4 is fully expanded and no further fluid is receivedtherein, the fluid supply is removed and the fluid is drained. In thismanner, the expanded tube 4 frictionally anchors into and/or against thesurrounding rock R.

The cover 22 may take the form of a plug or a cap. In one embodiment,the cover 22 is a plug 122 or a plug 222, as shown in FIGS. 4 and 5,respectively. The plug 122, 222 is placed in the opening in the distalend 23 of tube 20 such that a first portion 124, 224 thereof is exposedand a second portion 125, 225 is in the interior of the tube 20. Theplug 122, 222 may take any suitable shape (such as rounded) as long asthe main passageway 26 is covered. The plug 122, 222 may be made ofsteel or any other suitable material. The plug 122, 222 may be fixed tothe rock bolt 102, 202 by welding or the like. For example, tack welds32, spaced apart around the circumference of the plug 122, 222 may beused to attach the plug 122, 222 to tube 20.

In one embodiment, such as for rock bolt 102, shown in FIG. 4, plug 122is spherical. Plug 122 may be placed such that the exposed portion 124is one hemisphere of spherical plug 122 and the second portion 125inside the opening in the distal end 23 of second stiffening tube 20 isthe other hemisphere as shown. Alternatively, the plug 122 may be placedsuch that less of plug 122 is exposed or more of plug 122 is exposed aslong as the main passageway 26 is covered. Plug 122 may take the form ofa polished or unpolished ball bearing.

In another embodiment, rock bolt 202, shown in FIG. 5, the exposedportion 224 of the plug 222 may be dome shaped and the second portion225 extending into tube 20 may be cylindrical. The second cylindricalportion 225 may further have a beveled edge 227 as shown.

Alternatively, the cover 22 may be a cap 322 or a cap 422, as shown inFIGS. 6 and 7, respectively. Cap 322, 422 may take any suitable shape(such as rounded) as long as the main passageway 26 is covered. The cap322, 422 may be made of steel or any other suitable material. Cap 322,422 may be fixed to the rock bolt 302, 402 by welding or the like. Forexample, tack welds 32 spaced apart around the circumference of theproximal end 329, 429 of cap 322, 422 may be used to attach cap 322, 422to respective tube 20.

In one embodiment, such as for rock bolt 302, shown in FIG. 6, cap 322is hemispherical, and the open proximal end 329 of cap 322 abuts distalend 23 of tube 20. Cap 322 is shown to be hollow but it could also besolid (not shown), for example, a sphere, such as plug 122 in FIG. 4,cut in half.

In another embodiment, such as for rock bolt 402, shown in FIG. 7, cap422 has a closed distal end 434, an open proximal end 429, and asidewall 436 extending from the closed distal end 434 to the openproximal end 429 creating an inner cavity 438. Cap 422 is placed overtube 20 such that tube 20 and the distal end 21 of tube 4 are receivedin the inner cavity 438. The sidewall 436 of cap 422 extends along thesidewall of tube 20. Cap 422 can be fabricated using any suitable meansincluding, but not limited to, stamping, molding, or attaching a coverportion to a cylindrical tube. The distal end 434 of cap 422 may behollow (as shown) or may be solid (not shown) as described above for cap322 of rock bolt 302.

In another embodiment (not shown), cap 422 could be sized such that itssidewall 436 fits inside the distal end 23 of tube 20 such that distalend 434 of cap 422 extends beyond distal end 23 of tube 20. A portion ofsidewall 436 may extend beyond the distal end 23 of tube 20 or thelength of the sidewall 436 may be adjusted so that only distal end 434extends beyond distal end 23 of tube 20.

The rock bolt can be made by providing an expandable member whichincludes an expandable tube 4 and an end fitting (stiffening tube 20) onthe distal end 21 of the expandable tube 4. The expandable tube 4 has alongitudinally extending depression 6 disposed between a pair of curvedouter portions of the tube 8, 10. The exterior of the tube defines atemporary, enclosed longitudinal passageway 26 having an open distal end23 and the outer portions of the tube 4 define internal passageways 28,30 which have closed distal ends 23. The distal end of the tube 4 isthen enclosed with a cover so as to cover the distal open end 23 of thetemporary, enclosed longitudinal passageway 26. The cover may be in theform of a plug 122, 222 or a cap 322, 422 and may be rounded. The covermay be secured to the expandable member by welding or any other suitablemethod. The method may also include placing a stiffening tube 20 on aproximal end 15 of the expandable member such that the stiffening tube20 surrounds the proximal end 15 of the expandable member and has anopening 34 that aligns with a corresponding opening in the expandabletube 4, thereby providing fluid communication to an interior of theexpandable tube 4. The stiffening tube 20 may be attached to theexpandable member by welding, crimping or any other suitable method.

The cover keeps debris from entering the main passageway of the rockbolt when the rock bolt is in the unexpanded condition. It also allowsthe rock bolt to be more easily inserted and centered in the borehole.The domed end of the rock bolt created by the cover eliminates the sharpangles at the distal end of the rock bolt which can tend to get caughton the sides of the borehole. The domed end also allows the rock bolt tobe centered more easily in the borehole.

The cover also has the advantage of reduced manufacturing costs comparedto other methods of rounding the end, for example, building up weldmetal on top of a blank to round the end. The cover may be held in placewith a minimal number of tack welds as described above simplifyingfabrication and reducing costs. In addition, manufacturing becomes eveneasier when producing a rock bolt according to embodiment 102, shown inFIG. 4. The spherical plug 122 may be placed in tube 20 in anyorientation simplifying assembly and, thus reducing assembly time.

The foregoing description sets forth the preferred embodiments of theinvention at the present time. Various modifications, additions, andalternative designs will, of course, become apparent to those skilled inthe art in light of the foregoing teachings without departing from thescope of the invention. The scope of the invention is indicated by thefollowing claims rather than by the foregoing description. All changesand variations that fall within the meaning and range of equivalency ofthe claims are to be embraced within their scope. Specifically, whileembodiments herein have been described as having a rounded cover, covershaving any shape that covers the main passageway of the rock bolt areconsidered within the scope of the invention.

The invention claimed is:
 1. A rock bolt comprising: an expandable tubethat is partially collapsed upon itself so as to form a longitudinallyextending depression between two longitudinally extending interiorpassageways, wherein the longitudinally extending depression forms atemporary main passageway at a distal end of the expandable tube,wherein the two longitudinally extending interior passageways form theinterior of the tube upon expansion, wherein the temporary mainpassageway is open at the distal end of the expandable tube, wherein thetwo longitudinally extending interior passageways are closed at thedistal end of the expandable tube, and wherein a pressurized fluid maybe delivered into the two interior passageways to force the depressionoutward to thereby expand the expandable tube and compress theexpandable tube against surrounding rock; an end fitting attached to thedistal end of the expandable tube, the end fitting having a sidewall andtwo open ends, a first of the open ends extending longitudinally beyondthe closed distal ends of the interior passageways; and a cover coveringthe first open end of the end fitting.
 2. The rock bold according toclaim 1, wherein the cover provides a rounded tip for the rock bolt. 3.The rock bolt according to claim 1, wherein the cover is a plug.
 4. Therock bolt according to claim 1, wherein the cover is a cap.
 5. The rockbolt according to claim 4, wherein the proximal end of the cap abuts thedistal end of the rock bolt.
 6. The rock bolt according to claim 4,wherein the cap comprises a closed distal end, an open proximal end, anda sidewall extending from the distal end to the open proximal end thatcreates an inner cavity, and wherein the cap is placed over the distalend of the rock bolt such that the distal end of the rock bolt extendsinto the inner cavity of the cap.
 7. The rock bolt according to claim 4,wherein the cap comprises a closed, distal end, an open proximal end,and a sidewall extending from the distal end to the open proximal endthat creates an inner cavity, and wherein the cap is placed into thedistal end of the rock bolt such that the proximal end of the capextends into the temporary longitudinal passageway of the rock bolt. 8.The rock bolt according to claim 1, wherein a central portion of thecover extends longitudinally from the first open end of the end fittinga greater distance than a peripheral portion of the cover extendslongitudinally from the first open end of the end fitting to facilitatecentering the rock bolt within a borehole.
 9. A method of manufacturinga rock bolt comprising: partially collapsing a tube upon itself so as toform a longitudinally extending depression between two longitudinallyextending interior passageways, wherein the longitudinally extendingdepression forms a temporary main passageway at a distal end of theexpandable tube; attaching an end fitting to the distal end of theexpandable tube, the end fitting having a sidewall and two open ends, afirst of the open ends extending longitudinally beyond the closed distalends of the interior passageways; closing the two longitudinallyextending interior passageways at the distal end of the expandable tube;and covering the first open end of the end fitting by affixing a coverto the end fitting.
 10. The method according to claim 9, wherein thecover provides a rounded tip for the rock bolt.
 11. The method accordingto claim 9, wherein the cover is a plug.
 12. The method according toclaim 9, wherein the cover is a cap.
 13. The method according to claim9, further comprising placing a stiffening tube on a proximal end of theexpandable member, wherein the stiffening tube surrounds the proximalend of the expandable member and has an opening that aligns with acorresponding opening in the expandable tube, thereby providing fluidcommunication to an interior of the expandable tube.
 14. The methodaccording to claim 9, wherein a central portion of the cover extendslongitudinally from the distal end of the first open end of the endfitting a greater distance than a peripheral portion of the coverextends longitudinally from the first open end of the end fitting tofacilitate centering the rock bolt within a borehole.
 15. A method ofusing a rock bolt comprising: providing a rock bolt comprising: anexpandable tube that is partially collapsed upon itself so as to form alongitudinally extending depression between two longitudinally extendinginterior passageways, wherein the longitudinally extending depressionforms a temporary main passageway at a distal end of the expandabletube, wherein the two longitudinally extending interior passageways formthe interior of the tube upon expansion, wherein the temporary mainpassageway is open at the distal end of the expandable tube, and whereinthe two longitudinally extending interior passageways are closed at thedistal end of the expandable tube; an end fitting attached to the distalend of the expandable tube, the end fitting having a sidewall and twoopen ends, a first of the open ends extending longitudinally beyond theclosed distal ends of the interior passageways; and a cover covering thefirst open end of the end fitting; drilling a borehole in rock; placingthe rock bolt in the borehole; expanding the tube by providingpressurized fluid to the two interior passageways of the expandabletube, thereby providing frictional engagement between an exterior of thetube and an interior of the borehole; and draining the fluid from theinterior of the tube.
 16. The method according to claim 15, wherein thecover provides a rounded tip for the rock bolt.
 17. The method accordingto claim 15, wherein the cover is a plug.
 18. The method according toclaim 15, wherein the cover is a cap.
 19. The method according to claim15, wherein a central portion of the cover extends longitudinally fromthe distal end of the first open end of the end fitting a greaterdistance than a peripheral portion of the cover extends longitudinallyfrom the first open end of the end fitting to facilitate centering therock bolt within a borehole.